Vacuum brazing process

ABSTRACT

This invention relates to an improved magnesium source for the vacuum brazing of aluminum members, the source comprising a magnesium-containing member clad with a magnesium-free aluminum alloy. The cladding effectively prevents the premature vaporization of the magnesium during vacuum brazing operations and also prevents the formation of a complex magnesium-containing oxide film on the magnesium source.

United States Patent Robinson Nov. 4, 1975 [54] VACUUM BRAZING PROCESS 3,321,828 5/1967 Miller 29/494 X 3,373,483 3/1968 Miller 29/501 [75] Inventor' 3,378,914 4/1968 Miller 29/494 Assignee: Kaiser Aluminum & Chemi al Schwartz et al. Corporation Oakland Calif 3,673,678 7/1972 Moreau et al. 29/494 [22] Filed: 1974 Primary ExaminerAl Lawrence Smith 21 APPL 53 494 Assistant Examiner-K. J. Ramsey Related US. Application Data Attorney, Agent, or FirmPaul E. Calrow; Edward J. Lynch [57] ABSTRACT This invention relates to an improved magnesium source for the vacuum brazing of aluminum members, the source comprising a magnesium-containing member clad with a magnesium-free aluminum alloy. The cladding effectively prevents the premature vaporization of the magnesium during vacuum brazing operations and also prevents the formation of a complex magnesium-containing oxide film on the magnesium source.

6 Claims, 4 Drawing Figures U.S. Patent Nov. 4, 1975 Sheet 2 of2 3,917,151

BRAZING SHEET OF THE INVENTION X3 BRAZING SHEET PRESSURE,TORR

F l G. 4

VACUUM BRAZING PROCESS This is a division of application Ser. No. 330,709, filed Feb. 8, 1973.

BACKGROUND This invention relates to the process of vacuum brazing metal products and, more specifically, relates to a clad product particularly useful in the vacuum brazing process.

The fluxless vacuum brazing process, which is basically described by Gunow et al. in U.S. Pat. No. 2,943,181, generally comprises subjecting the metal parts to be joined to the action of a reactive metal vapor in a high temperature, low pressure environment. Usually, a brazing alloy is disposed between the surfaces to be joined. The reactive metal vapor apparently removes substantially all remaining oxygen from the atmosphere surrounding the metal parts and also disrupts or removes any oxide film on the metal parts so that the oxide film does not interfere with the flow of brazing alloy at the operating temperatures. The vacuum brazing process can be employed to join many various metals, including steel, titanium, zirconium, aluminum and the like.

In the vacuum brazing of aluminum products, magnesium vapor has been almost exclusively used asthe gettering agent. The magnesium source can be magnesium metal which is placed in the furnace chamber prior to heat-up, but, most frequently, a brazing alloy is employed which contains significant amounts of magnesium. Conventional aluminum vacuum brazing sheet generally is a composite sheet comprising a core of 3003 aluminum alloy or 6951 aluminum alloy and a cladding of X4003 aluminum alloy, X4004 aluminum alloy or X4005 aluminum alloy. As used herein, all numbered aluminum alloys are the Aluminum Association designated alloys. The various commercially available vacuum brazing sheets are described below in Tables l and 2.

Table l Brazing Sheet Number* X3 X5 X7 X8 X9 X14 Core 3003 6951 3003 3003 3003 6951 l z iil c iing X4003 X4003 X4004 X4004 X4005 X4004 Alloy Aluminum Association Designation Table 2 Alloy Composition* (Per Cent by Weight) moreover reacts with any magnesium vapors remaining in the furnace atmosphere. Furthermore, in the typical operation of a semicontinuous vacuum furnace, intermittent loads of contamination, e.g., water or oxygen. enter the high vacuum chamber as new parts are introduced, and, thus, further contamination of activated surfaces may occur after the burst of magnesium vapor but prior to the melting and flowing of the brazing filler alloy. Moreau et al. in U.S. Pat. No. 3,673,678 sought to avoid the premature burst or vaporization of magnesium by backfilling the furnace with inert gas to retard at least part of the vaporization of magnesium until just before the brazing temperature is reached. While the method proposed may be fairly effective, furnace control is very difficult, particularly with semicontinuous vacuum brazing furnaces.

Low quality brazements are also frequently encountered when utilizing vacuum brazing sheet which has a magnesium-containing cladding. The unsound brazements are apparently due to the presence of a complex, magnesium-oxide-containing film on the surface of the brazing sheet which interferes with the flow or filleting of the brazing alloy. The magnesium vapors have little or no effect on this type of film. The film, which is formed under a variety of circumstances, for example, during annealing, can be removed mechanically. but this requires an additional, inconvenient process step.

Against thisbackground, the present invention was developed.

DESCRIPTION OF THE INVENTION The present invention provides an improved magnesium source for the vacuum brazing of aluminum products which significantly retards the vaporization of magnesium during furnace heat-up and also effectively precludes the formation of a magnesium oxide-containing film on the magnesium source. The magnesium source of the present invention is a magnesium-containing metal selected from the group consisting of magnesium metal, a'magnesium alloy or an aluminum alloy containing at: least 0.5 percent by weight magnesium which is clad with an essentially magnesium-free aluminum alloy; having a liquidus at least F. above the liquidus of the. magnesium-containing metal and preferably above thegbrazing temperature which normally ranges from about l,l00l,150F. As used herein, the term fmagnesium-free" refers to an alloy containing no more than 0.1% by weight magnesium.

In accordance with the invention during heat-up, the magnesium-containing metal melts and begins dis- Alloy Si Fe Cu Mn Mg Zn A1 3003 0.6 0.7 0.05 0.20 1.0 1.5 0.10 Balance 6951 0.2 0.5 0.8 0.15 0.40 0.10 0.4 11 0.8 020 Balance X4003 6.8 8.2 0.8 0.25 0.10 2.0- 3.0 0.20 Balance X4004 9.0 10.5 0.8 0.25 0.10 1.0 2.0 0.20 Balance X4005 9.5 11.0 0.8 0.25 0.10 0.20 1.0 0.20 Balance *Unless shown as a range. the composition is per cent maximum In commercial vacuum brazing operations, particularly with semicontinuous furnace operations, low qual-, ity brazed joints frequently result due in part apparently to the premature vaporization of magnesium in the furnace chamber. Apparently, air, which normally leaks into the furnace, recontaminates the surfaces which have been activated by magnesium vapors and solving the magnesium-free aluminum alloy cladding. Significant vaporization of magnesium does not occur until the cladding is penetrated by the underlying molten magnesium-containing metal. So long as the melting point requirements set forth above are met, the composition of the magnesium-free aluminum alloy cladding is not particularly critical unless the cladding 3 becomes an integral part of the brazed joint. No alloying constituents should be included in the magnesiumfree aluminum alloy cladding which will detrimentally of a brazed joint according to the invention;

FIG. 4 illustrates the improv'e'results of the invention."

With reference to FIGS. '1 and 2, preferably, the magnesium source of the present invention is a sheet product comprising an aluminum core 10, a magnesium containing (i.e., more than 0.5% Mg) brazing alloy layer 11 clad to the core l and a magnesium-free a'luminum alloy layer 12 clad'to the brazing alloy layer 11. As indicated in the Figures, one or both' sides of the core can be clad with the magnesium-containing and magnesium-free layers. The core and the'magnesiumfree'cladding alloys must have a liquidus considerably higher than the brazing alloy. The liquidus temperature of the magnesium free laye'r'is preferably not below the brazing temperature. The liquidus temperature of the core, of course, must be above the brazing temperature. The composition of the core and magnesium-free cladding alloys isnot particularly critical so long as the composition does not detrimentally affect the brazing process or brazed joint. Generally, the magnesium-free alloy and the core alloy should contain less than zinc, 0.8% iron, 1% silicon, 3% manganese, 0.5% chromium, 0.05% titanium and other elements 0.10% each. The core alloy may also contain magnesium up to 2.5%. The above limits generally relate to the alloying of individual elements'by themselves. Suitable alloys for the core andmagnesium-free cladding includellOO and 3003 aluminum alloys. Aluminum alloys 6951 and 7005 can also be used as core alloys. The brazing alloy is an aluminum alloy consisting essentially of about 5-l5percent by weight silicon; 0.5% to 5 percent by weight magnesium, 0.8 percent by weight maximum iron, 0.25percent by weight maximum copper, 0.20 percent by weight maximum zinc, 0.20 percent by weight maximum manganese-other elements 0.10 per-' cent by weight maximum each and the balance'aluminum. For most commercial applications, the sheet product will comprise a core which is clad on both sides with the magnesium-free alloy and the magnesium-containing brazing alloy. To facilitate cladding, interliners of thin, relatively pure aluminum, e.g., l 100 alloy, may be disposed between the various layers.

The thickness of the magnesium-free aluminum cladding depends to a considerable extent upon the magnesium burst temperature desired and the composition of the magnesium-containing alloy beneath the cladding. As indicated hereinabove, the magnesium-free cladding must be dissolved away at least in part by the magnesium-c'ontaining underlayer during heat-up to brazing temperatures. Subject to the above. the thickness of the magnesium-free layer generally can range from' about 000001 to about 0.25 inch. Usually, the thickness of the magnesium-free cladding ranges from about 0.1 to percent of the thickness of the magnesiumcontaining-alloy member. Cladding thicknesses be' low ventional roll bonding techniques. Substantially all commercially available aluminum vacuum brazing sheet is below 0.1 inch in' thickness because to date most vacuum brazing has been limited to joining relatively thin members. However, vacuum brazing can be conducted successfully on thick membersif it is so desired.

The preferred embodiment of the present invention is most conveniently prepared by cleaning the mating surface to remove excessoxide, grease, dirt and the like, heating to a temperature between about 600to 900F. and then roll bonding. The magnesium-free layer is first roll bonded to the magnesium-containing,

surfaces and then this clad product is roll bonded to the core. To facilitate the formation of a good metallurgical bond during fabrication, it is sometimes desirable to interpose thin layers of relatively pure aluminum, e.g., l 100 alloy, between the various members prior to bonding. l

In accordance with a preferred embodiment of the present invention, aluminum members to be joined are positioned in the desired relationship with the vacuum brazing sheet of the present invention in contact with at least-one of the parts to be joined. The assembly is then 1 subjected to temperatures between about ll00 and 1 150F. anda pressure less tharilO Torr 10 microns of mercury at 0C.) until the brazing alloy layer in the vacuum brazing sheet melts, dissolves the overlying magnesium-free layer and flows, thereby forming a fillet with the part in contact with said sheet. The assembly is then cooled to allow the thus-formed fillet to so-= lidify As a general rule, the quality of a brazed joint is a function of the radius of the fillet which forms at the joint during brazing. This radius, is shown in FIG. 3

about 0.0001 inch are very difficult'to obtain by con-"' which illustrates'a typical brazed joint. Generally, the larger the radius of the fillet, the higher the quality of the brazement. For commercially acceptable T-joints and the like, the radius of the fillet must usually'exceed the thickness of the part to be brazed and for high quality brazements, the radius is preferably greater than twice the thickness. However, heretofore, to obtain a large radius, the contaminant level in the furnace must be kept extremely low, thus requiring extremely low pressures. For example, for most commercial furnaces, the pressure -'must be maintained at less than about 5X10 Torr (SXlO microns), preferably around 1X10 Torr (lXlO microns), to obtain high quality brazements. With the magnesium source of the present invention, it has been found that sound commercially acceptable brazements can be obtained at pressures as high as 2X 10 Torr (0.2 micron). Some brazing occurs at pressures as high as 10 Torr (10 microns). Moreover, because the product of the present invention is clad with essentially magnesium-free aluminum alloy, no complex magnesium oxide-containing films are formed on the product which can detrimentally affect the quality of the brazed joint.

To illustrate the advantages of the present invention, several T-joint brazeme nts were made utilizing the preferred vacuum brazing sheet of the present invention and No. X7 Brazing Sheet with the joint construction shown in FIG. 3. The vacuum brazing sheet of the present invention comprised a core of 3003 alloy 0.014 inch thick, a brazing alloy (X4004) 0.003 inch thick clad to both surfaces ofthe core, and a surface cladding of 3003 alloy 0.00005 inch thick The" No. X7 Brazing 7 Sheet was 0.02 inch thick with thecladding being 15 5 6 percent of the composite thickness. Conventional prebrazing alloy to dissolve said magnesium-free cladtreatrnents and brazing practices were employed. The ding and thereby allow the magnesium in said brazbrazing was conducted at ll30F. and at various presing alloy to vaporize;

sures ranging from about lXl Torr microns) C. maintaining said brazing temperature until said to about 5X10 Torr (5 10 micron). The fillet radii 5 brazing alloy has flowed into contact with said part formed at the various pressures were measured to obin contact with the brazing sheet so as to form a filtain an indication of the soundness of each of the joints. let therewith; and These are indicated below in Table 3. D. cooling the assembly to solidify the brazing alloy. Table 3 10 2. process for vacuum brazing aluminum parts comprising. Fine Radius, in a. assembling an aluminum part to be joined in the -5 ff ff5 5x104 desired relationship and in contact with an alumi- No X3 Bram num brazing sheet having a brazing alloy cladding;

' Sheet g 0048 0016 0002 No Bond b. placing said assembled members in a chamber ca- Brazing Sheet of pable of sustaining a vacuum and in close proximity 005 0018 0902 to said assembled members a magnesium source comprising a metal base containing at least 0.8 percent by weight magnesium, said metal base se- As indicated by the data, the vacuum brazing sheet of lected from the group Consisting f aluminum the present invention allows for a magnitude higher loys and magnesium or magnesium alloys and hayp than sfahdard vacuum brazing ing bonded to the surface of said metal base a mag- 1053 the qh y of the Weldmehts- Thls data 15 shown nesium-free aluminum alloy having a melting point pl y In of at least 50F. higher than said metal base;

It IS obvious that various modifications and improvesubjecting the assembled members and id ments can be made to the present invention without denesium Soul-Ce to a pressure h 10- 'T f parting from the spirit of the invention or the scope of mercury b l the appended claims- (1. heating the assembled members and said magnewhat is Claimed is: sium source to brazing temperature so as to melt 1. The process of vacuum brazing alu P said brazing alloy on the brazing sheet and to cause comprising said metal base to dissolve the magnesium-free assembling a P to he joined in the desired cladding on the surface thereof and thereby allow tionship and in contact with a vacuum brazing th magnesium i aid tal ba e to vaporize; sheet comprising an aluminum alloy core, Clad t0 e. maintaining said brazing temperature until said Said Core 21 brazing alloy Consisting essentially of brazing alloy has flowed into contact with said aluabout 5 to 15 percent by weight silicon, about 0.5 minum part in contact with the brazing sheet so as to 5 percent by weight magnesium, 0.8 percent by to form a fillet therewith; and

weight maximum iron, 0.25 percent by weight maxf. cooling the assembly to solidify the brazing alloy. imum copper, 0.20 percent by weight maximum 3. The method of claim 1 wherein said pressure is less zinc, 0.20 percent by weight maximum manganese, than 5 X 10 Torr. 0.1 percent by weight maximum other elements 4. The method of claim 2 wherein said pressure is each and the balance aluminum and clad to said maintained less than 1 X 10 Torr.

brazing alloy a magnesium-free aluminum alloy, 5. The method of claim 2 wherein said assembly and said magnesium-free alloy having a melting point at magnesium source is subjected to temperatures beleast llOOF.; tween about 1l00 and ll50F.

B. subjecting the assembled parts to a pressure less 6. The method of claim 1 wherein the thickness of than 10 Torr of mercury (absolute) and heating said magnesium-free aluminum alloy ranges from about the part and the brazing sheet to brazing tempera- 0.00001 to about 0.25 inch.

ture to melt said brazing alloy and to cause said UNITED STATES PATENT @FFHIE QETH ECATE F QGRECTIN 0 PATENT NO. 1 3,917,151

DATED 1 November 4, 1975 INVENTORtS) 1 Ivan B. Robinson It is certified that error appears in the above-identified patent and that said Lettets Patent g are hereby corrected as shown below:

Column 1, in /Table 2, Alloy 6951, .under the column for Mg, "0.4 110.8"

should read 0.4 0.8

., Signed and ficalcd this twenty-third Day of March 1976 [SEAL] Atlest.

RUTH c. ASON c. MARSHALL DANN J Atleslmg Officer Commissioner ufPatents and Trademarks 

1. The process of vacuum brazing aluminum parts comprising A. assembling a part to be joined in the desired relationship and in contact with a vacuum brazing sheet comprising an aluminum alloy core, clad to said core a brazing alloy consisting essentially of about 5 to 15 percent by weight silicon, about 0.5 to 5 percent by weight magnesium, 0.8 percent by weight maximum iron, 0.25 percent by weight maximum copper, 0.20 percent by weight maximum zinc, 0.20 percent by weight maximum manganese, 0.1 percent by weight maximum other elements each and the balance aluminum and clad to said brazing alloy a magnesium-free aluminum alloy, said magnesium-free alloy having a melting point at least 1100*F.; B. subjecting the assembled parts to a pressure less than 10 2 Torr of mercury (absolute) and heating the part and the brazing sheet to brazing temperature to melt said brazing alloy and to cause said brazing alloy to dissolve said magnesium-free cladding and thereby allow the magnesium in said brazing alloy to vaporize; C. maintaining said brazing temperature until said brazing alloy has flowed into contact with said part in contact with the brazing sheet so as to form a fillet therewith; and D. cooling the assembly to solidify the brazing alloy.
 2. A PROCESS FOR VACUUM BRAZING ALUMINUM PARTS COMPRISING: A. ASSEMBLING AN ALUMINUM PART TO BE JOINED IN THE DESIRED RELATIONSHIP AND IN CONTACT WITH AN ALUMINUM BRAZING SHEET HAVING A BRAZING ALLOY CLADDING, B. PLACING SAID ASSEMBLED MEMBERS IN A CHAMBER CAPABLE OF SUSTAINING A VACUUM AND IN CLOSE PROXIMITY TO SAID ASSEMBLED MEMBERS A MAGNESIUM SOURCE COMPRISING A METAL BASE CONTAINING AT LEAST 0.8 PERCENT BY WEIGHT MAGNESIUM, SAID METAL BASE SELECTED FROM THE GROUP CONSISTING OF ALUMINUM ALLOYS AND MAGNESIUM OR MAGNESIUM ALLOYS, AND HAVING BONDED TO THE SURFACE OF SAID METAL BASE A MAGNESIUM-FREE ALUMINUM ALLOY HAVING A MELTING POINT OF AT LEAST 50*F. HIGHER THAN SAID METAL BASE, C. SUBJECTING THE ASSEMBLED MEMBERS AND SAID MAGNESIUM SOURCE TO A PRESSURE LESS THAN 10**-2 TORR OF MERCURY (ABSOLUTE), D. HEATING THE ASSEMBLED MEMBERS AND SAID MAGNESIUM SOURCE TO BRAZING TEMPERATURE SO AS TO MELT SAID BRAZING ALLOY ON THE BRAZING SHEET AND TO CAUSE SAID METAL BASE TO K DISSOLVE THE MAGNESIUM FREE CLADDING ON THE SURFACE THEREOF AND THEREBY ALLOW THE MAGNESIUM IN SAID METAL BASE TO VAPORIZE, E. MAINTAINING SAID BRAZING TEMPERATURE UNTIL SAID BRAZING ALLOY HAS FLOWED INTO CONTACT WITH SAID ALUMINUM PART IN CONTACT WITH THE BRAZING SHEET SO AS TO FORM A FILLET THEREWITH, AND F. COOLING THE ASSEMBLY TO SOLIDIFY THE BRAZING ALLOY.
 3. The method of claim 1 wherein said pressure is less than 5 X 10 5 Torr.
 4. The method of claim 2 wherein said pressure is maintained less than 1 X 10 5 Torr.
 5. The method of claim 2 wherein said assembly and magnesium source is subjected to temperatures between about 1100* and 1150*F.
 6. The method of claim 1 wherein the thickness of said magnesium-free aluminum alloy ranges from about 0.00001 to about 0.25 inch. 